Increase System Efficiency with Condition Monitoring. Embedded Control and Monitoring Summit National Instruments

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1 Increase System Efficiency with Condition Monitoring Embedded Control and Monitoring Summit National Instruments

2 Motivation of Condition Monitoring Impeller Contact with casing and diffuser vanes Bent Diffuser Vanes Bending failure of gear teeth- seized rotor

3 Types of Machine Failures The many Sources of machinery vibration Sources of Mechanical Failure Each has a unique signature which can be learned using a simulator. Source: Machinery Noise and Diagnostics by Richard H. Lyon

4 What is Condition Monitoring

5 What is Condition Monitoring Machine Health Preventative Maintenance Predictive Maintenance Acceptable Operating Zone Run to- Failure Time

6 Machine Availability

7 Why Condition Monitoring? Increase customer confidence Increase production output Reduce scrap and raw material use Increase product quality Reduce repair time and spare parts Lengthen maintenance cycle Stop unscheduled outages Optimize machine performance Prevent catastrophic failure Avoid injury, environmental harm Increase Revenue Quality Control Reduce Costs Production Assurance Safety

8 Machine condition What to Monitor and Test Conditions start to change Vibrations Noise Heat Smoke Emergency stop Time 10 min Credit F IS 3 month 2 weeks 2 days

9 What to Measure Location (GPS) Temperature Electrical Power Vibration Strain

10 Condition Monitoring Signal Sources Imbalance Vibration Acoustic Emissions Vibration Electrical Power Temperature Fluid Analysis Strain

11 Velocity (ips) Basic Fault Frequency Analysis unbalance misalignment bearing frequencies gear mesh frequencies Frequency (Hz)

12 Order Analysis Resample frequency information to order information 1k 2k 3k 4k 5k Frequency Order

13 Order Analysis 1x 1x 2x Imbalance Misalignment 1x GM 1x 2x 3x 4x Gear Wear Looseness

14 Additional Signal Processing Waterfall Colormap Orbit Plot Shaft Centerline Envelope Analysis Limit Masks

15 Types of Monitoring Today Market Size (In Millions $) Test, $50 Handheld, $100 Portable, $90 Protection, $400 Online, $260 Source: Frost and Sullivan Market Survey

16 Wireless Sensor Nodes Wirelessly transmit basic analytics Low power permanent devices Low channel counts Only works for local distributions

17 Portable More advanced analysis Larger channel counts Usually used with a laptop

18 Online Embedded intelligence Limited signal processing 10 s of channels High fidelity data

19 Protection Triggers machine shutdown Safety certifications required

20 Challenges in the Application Today Data overload Remote locations Prognostics

21 TDMS File Format Read TDMS Files in Excel, Math Packages, C, etc.

22 Remote Data Collection Assets are geographically distant Analysts spend too much time collecting

23 Remote Data Collection Data acquisition Vibration Temperature Strain Voltage 4-20 ma Onboard computer decision based data logging Onboard storage Communication TCP/IP FTP Modbus Rugged casing

24 Embedded Condition Monitoring System Sensors Communication Protocols Onboard Analysis and File Recording User Interface and Configuration Signal Conditioning Data Acquisition Remote Storage and Analysis

25 Prognostics Confidence Value for performance degradation assessment (CV ~ 0-1) Health Radar Chart for multiple components degradation monitoring Health Map for potential issues and pattern classification Risk Radar Chart to prioritize maintenance decision

26 Feature 2 IMS Instrumentation Approach CRITICAL ASSET DATA ACQUISITION / SIGNAL PROCESSING FEATURE EXTRACTION & SELECTION 9 8 Baseline Current Data Feature 1 HEALTH VISUALIZATION PERFORMANCE PREDICTION HEALTH ASSESSMENT

27 scales a Signal Processing & Feature Extraction Raw Vibrations Stationary Raw Vibrations Signal Processing & Feature Extraction Time Domain Analysis Frequency Domain Analysis Time-Frequency Analysis Wavelet/Wavelet Packet Analysis Principal Component Analysis (PCA) Non-Stationary Timesynchronous Average FFT + Envelope Wavelets CWT of time synchronous signal for gearbox with broken tooth (File 105) Time (for 1 revolution)

28 Watchdog Agent Prognostics Toolkit for LabVIEW

29 Sound and Vibration Measurement Suite Vibration Measurements Tachometer Analysis Signal Processing Visualization

30 Sound and Vibration Measurement Suite Optimized for Embedded Similar functionality Analysis only, no GUI

31 NI CompactRIO Rugged Industrial Form Factor Mixed Measurement Types Onboard Signal Processing Real-Time Computer and Storage Open Communication Standards Module Based Solution for Custom Systems

32 Measurement Modules Accelerometer Strain Gauge Load Cells Digital I/O Microphone DC Voltage Thermocouples 4 to 20mA Time (GPS) RTD Resistance Power (Volts/Amps)

33 Online Monitoring of Nuclear Power Products: Sound and Vibration, LabVIEW, NI CompactRIO Reactors Wired Network Wireless Receiver Wireless Repeater WRLSS059-2 The Challenge: Developing an online monitoring (OLM) solution for boiling water reactors, which contain machinery in hazardous and difficult-to-access areas. Data Acquisition and Analysis Workstation Wireless Transmitter Wireless Transmitter The Solution: Using an integrated, embedded NI CompactRIO system to develop the EWV-1 and OLM-32 hardware to provide live, wireless monitoring of plant assets in conjunction with AMS monitoring software A T S Accelerometer Temperature Sensor Speed Sensor

34 Open Pit Mining Shovels Products: Sound and Vibration, LabVIEW, NI CompactRIO The Challenge: Developing a highly specialized continuous monitoring system for electromechanical mining shovels to enable a predictive maintenance strategy for these critical machines. The Solution: Creating a fully functional, tailormade vibration and stress continuous monitoring system using the NI CompactRIO platform and NI LabVIEW software.

35 Demonstration Embedded Vibration Monitoring Tachometer X Accelerometer Y Accelerometer TCP/IP Communication

36 Thank you for attending the NI Embedded Technology Summit For more information, please visit

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